SolutionCell Barrett Boike Boeing-Mar2014

The University of Kansas
Adaptive Aerostructures Laboratory

ITAR /EAR unrestricted
The University of Minnesota

College of Biological Sciences
Increasing Allowable UAV Gross Weight and Expanding Operating Conditions via SolutionCell Pressure Adaptive Honeycomb
by
unclassified Copyright R.M. and C.M. Barrett 2013 all rights reserved
Ron Barrett
The University of Kansas, Lawrence Aerospace Engineering Department and
Sean Paul Boike

President American Industrial Consultants
Boeing Phantom Works 26 February 2014
Unclassified
distribution unlimited
R. Barrett
All Rights Reserved
rev. 28 February 2010


Outline
1. Introduction & Motivation 2. Biological Models for Advanced Adaptive Actuators 3. PAH Materials Development 4. PAH Wing Applications 5. Operational Envelope, Allowable Weight & Performance Implications 6. LO Implications
1.Introduction Models 4.Wing 5. Performance 6. LO Unclassified 2.Bio. distribution unlimited 3. Materials R. Barrett All Rights Reserved rev. 28 February 2010
Copyright R.M. and C.M. Barrett 2013 all rights reserved
unclassified


Motivation: The same as nature

T/O & Landing: Maximize CLmax, Reject Gust Loading Cruise: Maximize L/D
unclassified
Cruise: T/O & Landing: Supercritical/NLF Airfoil Section High Camber & t/c Wing Area, Camber & t/c Reduction Blunt Leading Edge Increased Sweep Angle Low Wing Sweep 1.Introduction Actuators 3.Art.Muscles 4.Aerospace 5.Automotive Unclassified 2.Nat. distribution unlimited R. Barrett All Rights Reserved rev. 28 February 2010


Successful Applications of Biomimicking Adaptive Materials In the Aerospace Industry:

Weapon Systems
unclassified
Piezoelectric, Shape-Memory-Alloys, Electroluminiscent Materials...

Adaptive Aerostructures Laboratory College of Biological Sciences Successful Applications of Biomimicking Adaptive Materials In the Aerospace Industry:
UAVs & Hovering Missiles
unclassified
1.Introduction Actuators 3.Art.Muscles 4.Aerospace 5.Automotive Unclassified 2.Nat. distribution unlimited R. Barrett All Rights Reserved rev. 28 February 2010

Adaptive Aerostructures Laboratory College of Biological Sciences Successful Applications of Biomimicking Adaptive Materials In the Aerospace Industry:
Disappearing UAVs
unclassified


Aerospace Morphing Concepts (cont.)

Planform Morphing
www.nextgenaeronautics.com 2008
Section Morphing
Gould et al. 1981
unclassified
M i s s iA on dapt i W ve i ng
1980s: Mission Adaptive Wing
www.geocities.com 2008
Pendelton et al. 1981
University of Florida
1990s: NASAs AAW Lockheed Martin


Adaptive Materials & Structures

Shape Memory Alloys Piezoelectric Materials
unclassified
Air Muscles
McMurtry 2004


Conventional Adaptive Materials

Current range of actuator materials available
Can they be used in commercial aircraft as a class? ...or in primary structure?
unclassified


10
What Would an Aircraft Designer want if s/he could design an adaptive material???
An "Ideal" Adaptive Aeromaterial/Aerostructure:
Material capable of "huge" (>50+%?) strains Fully proportional, easily controlled Stiff & strong enough to handle "real" loads Lighter than conventional aircraft actuation systems
unclassified
Faster than conventional aircraft actuation systems

Less costly & lower drag than conventional aircraft actuation systems No dedicated power consumption Self-diagnostic, self-repair capability Certifiable under FAR 23/25, 27/29 1.Introduction Models 4.Wing 5. Performance 6. LO Unclassified 2.Bio. distribution unlimited 3. Materials R. Barrett All Rights Reserved rev. 28 February 2010


11
Solution? ...Biomimetics
unclassified
"You should pay attention to what Mother Nature has done because she's got a 4.2 billion year lead in research and development.
-Prof. H.W. Smith, PE, Ph.D.


12
Fast-Response Actuators in Eukaryotes

Animal Muscle Cells and Tissues
unclassified
Fast-Acting Plant Cells and Tissues


13

Animal Muscle Cell & Tissues
unclassified


14

Mechanical Analogs of Animal Muscle Tissues: -Shape-Memory-Alloys -Pneumatic Tubes -Piezoelectric Polymers -Adaptive Gels -Electrostatic Actuators
unclassified

Solution: Adaptive Aerostructures Laboratory College of Biological Sciences Actuators Made from 100% FAA-Certifiable materials, but arranged like fast-acting plant cells
15
unclassified
1.Introduction Actuators 3.Art.Muscles 4.Aerospace 5.Automotive Video Credit: 2.Nat. & C.M. Barrett Unclassified distribution unlimited R. Barrett All Rights Reserved rev. 28 February 2010


16
Solution: FAA-Certifiable Actuators based on Plant Cell Structures
unclassified
Albizia julibrissin


17
unclassified
Pulvinus


18
unclassified
Ground Cells
Phloem
Xylem

Solution: Adaptive Aerostructures Laboratory College of Biological Sciences Actuators Made from 100% FAA-Certifiable Materials, but arranged like fast-acting plant cells
19
unclassified
1.Introduction Actuators 3.Art.Muscles 4.Aerospace 5.Automotive Video Credit: 2.Nat. & C.M. Barrett Unclassified distribution unlimited R. Barrett All Rights Reserved rev. 28 February 2010
unclassified
Solution: Adaptive Aerostructures Laboratory College of Biological Sciences FAA-Certifiable Actuators based on Plant Cell Structures
20


21

Fundamental Structural Arrangement:
unclassified
unclassified
Biomimetic Honeycomb Based on Plant Actuator Cells

Adaptive Aerostructures Laboratory College of Biological Sciences
22
Easily modeled, light, strong
Made of conventional materials (aluminum, steel, aramids)

Already known and accepted by certifying agencies like the FAA
Unclassified distribution unlimited R. Barrett All Rights Reserved rev. 28 February 2010


23
Biomimetic Plant-Cell Based Honeycomb Actuator
After: Olympio et al. 2007
Standard
Auxetic
Hybrid


24
Pressure Adaptive Honeycomb (PAH) Breakdown for Modeling
unclassified


25
PAH Geo-Kinematic Properties
unclassified
CDP = Cell Differential Pressure


26
PAH Cell Modeling
unclassified


27
PAH Cell Modeling
unclassified


28
PAH Linear-Elastic Modeling Background

Cellular Material Theory (CMT) after Gibson et al. 1988 Considerations: l Only valid for small thickness-to-length ratio t qi Only valid for +/- 20% of strain Linear stress-strain relationship
unclassified


29
PAH Linear-Elastic Modeling Background
unclassified


30
PAH Theoretical Characterization

Global stress-strain relations: @ constant pressure:
unclassified
@ constant mass:
with


31
PAH Theory, Experiment & Correlation
unclassified


32
PAH Nonlinear Mechanics
unclassified


33
PAH Single-Cell Tension-Compression Test
unclassified


34
PAH Longitudinal Stress-Strain Correlation
unclassified
p = 55kPa
p = 60kPa


35
PAH Single-Cell Tension-Compression Test
unclassified


36
PAH Four-Cell Tensile Test of Steel Honeycombs
unclassified


37
PAH Four-Cell Tensile Test of Steel PAH
unclassified


38
Experimental PAH Stress-Strain Relations
unclassified


39
PAH Multi-Cell Compression Test
unclassified


40
Non-linear Mechanics of PAH Structures
unclassified


41
Effects of Different PAH Boundary Conditions
unclassified


42
Multi-Cell Compression Test
unclassified
180mm


43
PAH Bender Experimental Characterization

Validation Experiment: Three-point bend test
unclassified
FEM Modeling:


44
Comparison to Other Adaptive Materials and Actuators

Conventional Hydraulic Actuators
unclassified
High Pressure Adaptive Honeycomb
Atmospherically Triggered Adaptive Honeycombs
unclassified
The University of Minnesota A New Approach to Flight Control... Adaptive Aerostructures Laboratory College of Biological Sciences Based on Nature: The University of Kansas
45
PAH employs distributed, rather than concentrated actuation...


46
Distributed airloads
Current Aircraft Actuator Design Philosophy
Control surface loads concentrated at finite hard points

Loads transferred through actuators & tracks
unclassified
Loads redistributed into primary structure


47
PAH Actuator Design Philosophy
Control surface loads stayed distributed Distributed control surface loads passed thru distributed actuators Distributed loads transferred to primary strucure


48
Comparison of PAH to Adaptive Materials and FAA Certified Actuators

High Pressure Adaptive Honeycomb
unclassified
Conventional Hydraulics & Pneumatics


49
unclassified
Unclassified
R. Barrett
All Rights Reserved


50
Pressure Adaptive Wing Section
2013 all rights reserved and C.M. al. 2007 Copyright R.M. Murray et Barrett
unclassified


51
Pressure-Adaptive Flap in Wind Tunnel (cont.)
unclassified
0kPa CDP
40kPa CDP


52
PAH Wing Section: Controllable Aerocompliance

Balanced Stiffness Cell Differential Pressure (BCDP) = 39 psi
Commanded TE Deflection 8 4 0 -4 -8
unclassified


53

UnBalanced Stiffness Cell Differential Pressure (UCDP) =
Commanded TE Deflection = 0 20psi 39psi 30psi
unclassified
10psi
0 psi


54
PAH Wing Section... foundations

Aerocompliance Background
Quasi-Rigid Airfoils 1800's Quasi-Rigid Flap Systems 1920's Aerocompliant Devices: HP-Slats, Blow-down tabs etc. Dynamically Aerocompliant Wings 1990's
unclassified
a(t)
q(t)
a(t)
q(t)
CL a CL=(a)
CL a CL=(a, df)
CL a CL=(q, a, df)
CL a CL(t)=(q(t),a(t), Ew)


55

New... Adaptive Aerocompliance & Commanded Lift Flight
"Practical" aggregate shape bounds due to physical limits to aerocompliant dynamic reshaping
unclassified
"Ideal" Adaptive Aerocompliant, Commanded-Lift-Flight Aircraft
"Practical" Minimum Aggregate slope due to Aircraft CLa, CL(q) Lift Characteristics
Lc
Lc
L
Lc
a(t)
Lc
a(t)
Lc
a(t)
Lc
q(t)
q(t)
q(t)


56

Conventional: Adaptive Aerocompliant:
unclassified


57

Conventional CL-a curve: Adaptive Aerocompliant:
unclassified
L(t) = 2000l b
Design point: 10,000lb of lift:
L(t) = 0
Design point: 10,000lb of lift:
a(t) = 2
a(t) = 2


58
Aerocompliance: Key to Birds Wings and PAH
unclassified
Gust load relieving smoothes flight

Unclassified distribution unlimited R. Barrett All Rights Reserved rev. 28 February 2010


59

Aeromechanics Modeling Controllable K d do Cd
unclassified
do


60
Current Aircraft Technology in Gust Fields
unclassified


61
PAH Wings: Enhancing Ride Quality, Fatigue Properties & Flight Safety via Active Aerocompliance
unclassified


62
PAH Gurney Flaps & Winglets
unclassified


63
The Real Savings... from Class I Design Forward

Structure of a typical FAR-25 V-n Diagram
Commercial Aircraft Structural Weights are set by these points
unclassified
Gust Limits Maneuver Limits
Load Factor, n (g's)
+1 0 VS1 VA VC VD
-1
Flight Speed, Vflt (kts)

Gust Limits


64
Weight Saving Paradigm Shift:

Compression of Gust Lines to within Maneuver ...just like birds do, via dynamic aerocompliance
unclassified
+1 0 VS1 VA VC VD
-1


65

Compression of Gust Lines to within Maneuver ...just like birds do, via dynamic aerocompliance
unclassified
saving... 7 23% total aircraft structural weight!
+1 0 VS1 VA VC VD
-1


66

Large UAV Sea Level V-n Diagram
unclassified


67
Turbulence Intensity PAH Opens Airspace

Example 1/22/99 FL 531 to 605, 18:00Z
unclassified


68
Turbulence Intensity PAH Opens Airspace
unclassified


69
Reference: Boeing 787

$32B investment in new product RDT&E: Just over half of the RDT&E was devoted to new materials & manufacturing
to achieve a ~20% weight reduction WRT conventional materials
unclassified


70
PAH Implications for GA UAVs

Implications for Predator/Avenger Lines: Increase in allowable gross weight by: Peak - Maneuver g's Increase in operational range by: Sp.Range * (Pk Man. g's)
unclassified
Increase in operational flight conditions by: above Airframe life extension
LO Decrement


71
LO Aircraft Door Applications

Hinges, push-rods, locking mechanisms, latches boost open-door RCS
unclassified
PAH door actuators and locking Mechanisms can be made from RAM cellular structure, dropping open door RCS


72
Related Technology: LO Vortex Generators

Vortex Generator Relative Performance
Tri-Rib
Tapered Tetrahedral Wishbone Ramp Tapered Vane
unclassified
Rectangular Vane
Triangular Plow Scoop Shielded Plow Simple Plow
Dome
0 0.5 1 1.5 2
Boundary Layer Energization/Drag Increment

(Optimum Size & Spacing)


73

"Smart" VGs up when needed, stowed flush when not needed
Installation fabrication & operation very similar to de-icer boots Fail-safe two modes: i. Semiactive atmospheric deployment ii. Active systemic optimization Easy integration/no primary structure penetration New materials technologies used certifiable under even FAR-25, but unique to the Aerospace community Proven VG Configuration Cessna 208, S2R, UV-23
US & International Patents Pending under Boeing, KU, Ikhana & DARCorp.
unclassified


74

1. Inboard LE TTVG Retrofit: Passive Only, RCS Reduction Passive TTVG's: 30% lower drag Active STVG's: 100% lower drag
unclassified
2. Crossflow Upper Surface Retrofit Fully Active, Semiactive or Passive RCS & Drag Reduction 3. Cmde Upper and Lower Surface Retrofit Fully Active, Semi-Active or Passive for RCS & Drag Reduction 1.Introduction Models 4.Wing 5. Performance 6. LO Unclassified 2.Bio. distribution unlimited 3. Materials R. Barrett All Rights Reserved rev. 28 February 2010


75

Upper Wing lobes ~150m2 RCS Increment
unclassified


76

Avenger Applications... PAH empennage: stabilization
unclassified
LO VG's:
boattail & interference drag cleanup
PAH flight control surfaces for LO
Useful load increase

Reduction in operational limitations LO PAH weapon bay door actuators


77
Acknowledgements
unclassified
Prof. Roelof Vos
NASA Ames Research Center
1.Introduction Actuators 3.Art.Muscles 4.Aerospace 5. Impact Unclassified 2.Nat. distribution unlimited R. Barrett All Rights Reserved rev. 28 February 2010


78
Questions?
unclassified
Unclassified
R. Barrett
All Rights Reserved


79
PAH Flap and Winglet System Implications

Implications for commercial jet fleets:
unclassified
Korean Air:
KRW11.807 trillion 2011 in operating expenses Retrofit Impacts: ~ +KRW200B (Net loss in 2011: KRW98B)
New Equipment Impacts: +KRW850B DOC savings + +KRW220B Airframe Life Extension + +KRW660B increased cargo carriage revenue ~ KRW1.7 trillion
European Patent EP 2459442 A2 US Patent 8,366,057 B2 February 2013


80
Aerospace Seating Applications

Rotary SolutionCell Seat Reclination Actuator
(20% conventional actuator weight) vertical seatback actuator geometry
unclassified
100psi CDP cells
Torlon-Aramid PAH substrate
100psi CDP cells
reclined seatback actuator geometry


81

ultra-low weight, compliant headrest actuators PAH Actuators ~20% of the weight of electromagnetic servoactuators
unclassified
conventional reclination actuators

ultra-low weight, conformal lumbar spine and sacral seat actuators conventional reclination actuators PAH Actuators with 10:1 extension capability conventional electromagnetic seat elevation, tilt actuators conventional electromagnetic jackscrew footrest actuators
R. Barrett All Rights Reserved rev. 28 February 2010
Unclassified


82

I.Business & First Class seats have between 2 and 14 actuators of different stroke and force capability. II.Replacement will yield a weight saving of between 1 and 16lb per seat
@ $750-$1,500/lb 787LCCsavings = $425-$850k
unclassified
III. Honeycomb used for crash energy absorption easily satisfies FAR 25.562
Unclassified
R. Barrett
All Rights Reserved


83
High Lift Mechanisms:

Conventional Actuators in new (22 year old) Conventional Adaptive Wing Concept:
Conventional actuators = heavy Not adaptively aerocompliant = minimal to adverse gust load alleviation optimization Not capable of negative section lift-curve slope generation No advantage in V-n diagram gust peak alleviation No ride quality improvement, aeromechanics enhancement and fatigue load alleviation Load concentration drives weight, increases complexity, cost Zone 1 lightning strike untested
unclassified
Unclassified
R. Barrett
All Rights Reserved

SolutionCell Barrett Boike Boeing-Mar2014

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The University of Kansas

Adaptive Aerostructures Laboratory

The University of Minnesota

Sean Paul Boike

Boeing Phantom Works 26 February 2014

All Rights Reserved

rev. 28 February 2010

The University of Kansas

The University of Minnesota

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota

Motivation: The same as nature

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota

Successful Applications of Biomimicking Adaptive Materials In the Aerospace Industry:

Copyright R.M. and C.M. Barrett 2013 all rights reserved

Piezoelectric, Shape-Memory-Alloys, Electroluminiscent Materials...

The University of Kansas

The University of Minnesota

UAVs & Hovering Missiles

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota

Aerospace Morphing Concepts (cont.)

Copyright R.M. and C.M. Barrett 2013 all rights reserved

1980s: Mission Adaptive Wing

Pendelton et al. 1981

1990s: NASAs AAW Lockheed Martin

The University of Kansas

The University of Minnesota

Adaptive Materials & Structures

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota

Conventional Adaptive Materials

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota

Copyright R.M. and C.M. Barrett 2013 all rights reserved

Faster than conventional aircraft actuation systems

The University of Kansas

The University of Minnesota

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota

Fast-Response Actuators in Eukaryotes

Copyright R.M. and C.M. Barrett 2013 all rights reserved

Fast-Acting Plant Cells and Tissues

The University of Kansas

The University of Minnesota

Fast-Response Actuators in Eukaryotes

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota

Fast-Response Actuators in Eukaryotes

Copyright R.M. and C.M. Barrett 2013 all rights reserved

The University of Kansas

The University of Minnesota